EP2957973B1 - Surveillance de position à base de lumière d'une station de travail - Google Patents

Surveillance de position à base de lumière d'une station de travail Download PDF

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Publication number
EP2957973B1
EP2957973B1 EP14180487.2A EP14180487A EP2957973B1 EP 2957973 B1 EP2957973 B1 EP 2957973B1 EP 14180487 A EP14180487 A EP 14180487A EP 2957973 B1 EP2957973 B1 EP 2957973B1
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EP
European Patent Office
Prior art keywords
bin
coordinates
light
process controller
control action
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Not-in-force
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EP14180487.2A
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German (de)
English (en)
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EP2957973A1 (fr
Inventor
John A. Lopetrone
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Fives Inc
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Fives Inc
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Classifications

    • GPHYSICS
    • G01MEASURING; TESTING
    • G01VGEOPHYSICS; GRAVITATIONAL MEASUREMENTS; DETECTING MASSES OR OBJECTS; TAGS
    • G01V8/00Prospecting or detecting by optical means
    • G01V8/10Detecting, e.g. by using light barriers
    • G01V8/20Detecting, e.g. by using light barriers using multiple transmitters or receivers
    • G01V8/26Detecting, e.g. by using light barriers using multiple transmitters or receivers using mechanical scanning systems
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23PMETAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P21/00Machines for assembling a multiplicity of different parts to compose units, with or without preceding or subsequent working of such parts, e.g. with programme control
    • B23P21/002Machines for assembling a multiplicity of different parts to compose units, with or without preceding or subsequent working of such parts, e.g. with programme control the units stationary whilst being composed
    • GPHYSICS
    • G05CONTROLLING; REGULATING
    • G05BCONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B23/00Testing or monitoring of control systems or parts thereof
    • G05B23/02Electric testing or monitoring
    • G05B23/0205Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults
    • G05B23/0218Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults characterised by the fault detection method dealing with either existing or incipient faults
    • G05B23/0243Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults characterised by the fault detection method dealing with either existing or incipient faults model based detection method, e.g. first-principles knowledge model
    • G05B23/0254Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults characterised by the fault detection method dealing with either existing or incipient faults model based detection method, e.g. first-principles knowledge model based on a quantitative model, e.g. mathematical relationships between inputs and outputs; functions: observer, Kalman filter, residual calculation, Neural Networks
    • GPHYSICS
    • G05CONTROLLING; REGULATING
    • G05BCONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00Program-control systems
    • G05B2219/30Nc systems
    • G05B2219/31From computer integrated manufacturing till monitoring
    • G05B2219/31027Computer assisted manual assembly CAA, display operation, tool, result
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02PCLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P90/00Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
    • Y02P90/02Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Definitions

  • the present disclosure pertains to light-based position control of a manual picking process.
  • US 2014/083058 A1 describes a system for storing and picking piece goods, comprising a work station, a motion-sensor that detects motion of an operator at the work station, and a computing unit configured to convert motion signals into trajectories, which are compared to reference trajectories to generate control signals indicating a correct or wrong performance to the operator.
  • WO 2012/109593 A1 describes a guide system having a controller and a projector, the controller including a plurality of addressed display features. An input signal is provided to the controller whereby an addressed display feature is selected based on the input signal and the projector projects a visual indicator onto a physical object.
  • US 2014/007419 A1 describes a device employed in a system for facilitating the assembly of a product by following an assembly sequence comprising several assembly steps.
  • the device comprises a presence sensor, a signalling member and a sequencer connected to the presence sensor and the signalling member, said sequencer comprising a microcontroller designed to manage said assembly sequence.
  • a system and method are described herein that use light-based position control in a manual picking process of the type described above. Unlike in fully-automated picking processes that closely control the sequential movement of a picking robot to minimize position error, manual picking processes are more prone to variance, for instance between different operators or at different times with respect to the same operator.
  • the present invention is intended to provide a highly repeatable quality level in such manual picking processes.
  • the system employs light-based position control steps and associated structural elements to ensure that an operator performs manual picking steps in a correct or expected order relative to a calibrated picking sequence.
  • a light device is positioned with respect to the workstation.
  • the light device projects one or more light beams in or along a fixed plane between the operator and a set of component bins, which are typically open-top boxes arranged in rows and columns within easy reach of the operator.
  • the plane is divided into a two-dimensional (2D) grid in logic of a process controller, with each segment or pixel of the 2D grid having a corresponding pair of coordinates, for instance XY coordinates in an example XYZ Cartesian frame of reference.
  • the coordinates of the broken light beam(s) are automatically detected via the light device and process controller.
  • the process controller which is programmed with a calibrated picking sequence defining a predetermined order of bin picking steps, each with a corresponding correct or "expected" component bin, may command an audio, visual, and/or tactile indication in response to the broken light beam(s). The nature of the indication depends on the location of the light beam breakage and the intended design.
  • an indicator device positioned within view of the operator or on the operator's person may activate.
  • An example lamp may illuminate in red or another suitable color, an audible alarm may sound, and/or a tactile response may be activated.
  • a text message may be displayed via a display screen alerting the operator that an incorrect bin access was attempted.
  • the same display screen may be used to cue the operator as to the location of the expected component bin for a given part of the calibrated sequence, or other cueing approaches may be used such as individual prompting lamps located on or within each of the component bins.
  • the process controller may be optionally programmed to record and track the efficiency of a given operator, with such efficiency data being useful for operator training, as well as for process or layout evaluation.
  • the system includes the process controller, the display screen, and the light device.
  • the light device is positioned with respect to the component bins, for instance directly overhead of the operator in an example laser scanner embodiment as detailed herein.
  • the light device projects one or more light beams in or along a fixed plane between the operator and the component bins.
  • the process controller which is in communication with both the light device and the display screen, may display part of a calibrated picking sequence via the display screen so as to cue the operator as to the correct next step in the picking process.
  • the light device and process controller are operable for detecting which light beams emitted by the light device are interrupted or broken, and for determining the corresponding 2D coordinates of the beam breakage(s).
  • the plane is divided into a virtual grid of segments or pixels, with each pixel having corresponding 2D coordinates that are matched to the calibrated sequence by the process controller to determine the "correctness" of the particular picking movement causing the beam breakage.
  • the process controller After identifying the 2D coordinates of the beam breakage(s), the process controller matches the identified 2D coordinates of the beam breakage(s) to corresponding boundaries of an expected component bin, again as determined by the calibrated sequence. If the location of the beam breakage(s) indicates that the operator is working within a permitted distance of the expected component bin, the process controller may execute a suitable control action such as illuminating an indicator device and/or presenting a message via the display screen.
  • the process controller may execute another suitable control action such as illuminating the indicator device in a different manner, such as illuminating a red light, and/or presenting a message on the display screen or one of the component binds prompting the operator to the expected component bin.
  • a method for controlling a position control system for a manual picking workstation having a plurality of component bins.
  • the method includes providing a calibrated assembly sequence and predetermined bin coordinates for each of the plurality of component bins, and projecting a light beam in or along a plane via a light device.
  • the method also includes detecting, via a process controller and the light device, an instance of beam breakage wherein the light beam is interrupted or broken, detecting two-dimensional (2D) coordinates of the beam breakage, and determining corresponding bin coordinates of an expected bin via the calibrated assembly sequence.
  • the process controller compares the determined 2D coordinates of the beam breakage to the corresponding bin coordinates of the expected bin, and executes a control action with respect to the manual picking workstation via the process controller when the determined 2D coordinates of the beam breakage do not match the corresponding bin coordinates of the expected bin.
  • a manual picking and assembly workstation 10 is shown schematically in FIGS. 1 and 2 .
  • the workstation 10 may include a process controller 12, a display screen 14, and a table 16 having a tabletop 18.
  • the tabletop 18 includes a work surface 20, e.g., a horizontal surface suitable for use by a human operator, shown at 40 in FIG. 2 , in assembling a subsystem or performing a kitting operation, as is well known in the art.
  • the light device 30 which is positioned with respect to the component bins 22, projects one or more light beams 32, whether visible or invisible to the naked eye, in or along a plane 32P located between the operator 40 and the component bins 22, with the plane 32P shown schematically in FIG. 2 .
  • the plane 32P is divided in logic of the process controller 12 into a virtual grid 52, with each segment or pixel of the grid 52 having a corresponding 2D coordinate pair, e.g., XY coordinates in an example XYZ Cartesian frame of reference.
  • the process controller 12 is programmed to execute instructions embodying a method 100, an example of which is shown in FIG. 4 , to provide the light-based position control noted above.
  • the light device 30 may be configured as any relatively low-power design providing a sufficiently wide detection angle ( ⁇ ), for instance 180°-270°.
  • sufficiently wide detection angle
  • other detection angles ( ⁇ ) may be used within the scope of the invention, provided that sufficient coverage is given to the component bins 22.
  • the light beams 32 must pass between the operator 40 and all of the component bins 22 whose access is being monitored, thereby providing the sufficient coverage.
  • the resolution of the light device 30 should be sufficiently high for precisely detecting the location of breakage of the plane 32P by a hand 42 and/or forearm 44 of the operator 40, such as 50-100 mm in an example embodiment.
  • the light device 30 shown in FIGS. 1 and 2 may be a set of fixed/non-oscillating horizontal and vertical linear light curtain devices LDV and LDH, respectively, as shown in phantom in Fig. 1 .
  • Such an embodiment may be used to project and receive horizontal light beams 32H and vertical light beams 32V.
  • stationary laser projector devices may be used to project the light beams 32H, 32V.
  • one light curtain device LDV projects while the oppositely-positioned device LDV receives. The same projecting-receiving pairing holds true for the horizontal devices LDH.
  • the system 50 may optionally include one or more indicator devices 48, e.g., a plurality of state lamps L 1 , L 2 , L 3 and/or an audio speaker S, with each state lamp L 1 , L 2 , L 3 being of a different color such as green, amber, and red, respectively. If a single state lamp L 1 , L 2 , or L 3 is used, a color-changing lens may be used to provide the same end effect.
  • the indicator devices 48, the light device 30, and the display screen 14 are all in communication with the process controller 12, with the process controller receiving input signals (arrows CC IN ) from the light device 30 and providing output signals (arrow CC OUT ) to the display screen 14 and/or the indicator devices 48 as needed.
  • the 2D coordinates of the location of such breakage of the light beam(s) 32 are detected by the light device 30 and transmitted to the process controller 12 as part of the input signals (arrows CC IN )
  • Software of the light device 30 needed for detecting such breakage may reside in the process controller 12, and if so, transmission of the input signals (arrows CC IN ) occurs within the process controller 12.
  • the process controller 12 is programmed with the calibrated sequence 45 defining the correct steps in a given bin picking process.
  • an example method 100 is described for using the system 50 shown in FIGS. 1 and 2 .
  • the workstation 10 of FIGS. 1 and 2 Prior to executing the method 100, the workstation 10 of FIGS. 1 and 2 is fully stocked with the necessary components or parts, such that the component bins 22 contain an adequate supply of the required components for completing the calibrated sequence 45.
  • the process controller 12 transmits the output signal (arrow CC OUT ) to the display screen 14 to thereby prompt the operator 40 as to the correct or "expected" component bin 22 or task step, e.g., "select component A from bin 1".
  • the method 100 then proceeds to step 104.
  • Step 104 includes detecting the 2D coordinates of any broken light beams 32. This portion of the method 100 determines when the operator 40 is reaching a hand 42 toward the component bins 22. The 2D dimensions of the broken light beam(s) 32 in the plane 32P are received by the process controller 12, which then executes step 106.
  • the process controller 12 determines whether the detected 2D coordinates from step 104 correspond to the coordinates of the expected component bin 22.
  • Step 106 may entail comparing the 2D coordinates of the beam breakage to coordinated defining the boundaries of the expected component bin 22, with the expected component bin 22 being determined by the calibrated sequence 45. For example, if the calibrated sequence 45 calls for the operator 40 to pick a component from bin 1 of FIG. 1 , the process controller 12 is programmed beforehand with the 2D boundaries for bin 1.
  • Step 106 in this instance could entail determining whether the 2D coordinates fall within the 23 boundaries for bin 1, e.g., via a simple direct comparison.
  • the method 100 proceeds to step 108 if the 2D coordinates do not fall within the boundaries for the corresponding expected component bin 22.
  • the method 100 otherwise proceeds to step 114.
  • Step 110 entails executing a suitable control action, for instance illuminating state lamp L 2 of FIG. 1 .
  • the state lamp L 2 may be an amber colored lamp in an example embodiment, or may have some other hue indicating that the operator 40 is close but not quite on target with respect to the expected component bin 22.
  • An audible warning tone may be sounded via the speaker S, and/or a message may be displayed via the display screen 14 to provide feedback to the operator 40.
  • Part of step 110 may entail illuminating the optional prompting lamp 25 on an expected component bin 22. The method 100 then proceeds to step 102.
  • Step 114 entails executing a suitable control action indicating that the result of step 106 is a correctly located component bin 22.
  • Step 114 may include illuminating the state lamp L 1 of FIG. 1 , for instance a green lamp or a lamp with an appropriate color indicating that the operator 40 is on target with respect to the expected component bin 22.
  • a confirming audible tone may be sounded via the speaker S as part of step 114, and/or a confirming text message may be displayed via the display screen 14 as in step 110.
  • the method 100 then proceeds to step 116.

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  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Evolutionary Computation (AREA)
  • Mechanical Engineering (AREA)
  • Automation & Control Theory (AREA)
  • Mathematical Physics (AREA)
  • Artificial Intelligence (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Geophysics (AREA)
  • General Life Sciences & Earth Sciences (AREA)
  • Automatic Assembly (AREA)
  • Laser Beam Processing (AREA)
  • Supply And Installment Of Electrical Components (AREA)

Claims (15)

  1. Système de commande de position pour un poste de travail à prélèvement manuel (10) possédant une pluralité de bacs de composants (22), comprenant :
    un dispositif lumineux (30) utilisable pour projeter un faisceau lumineux (32) le long d'un axe fixe (32P) ; et
    une unité de commande de processus (12) en communication avec le dispositif lumineux, dans lequel l'unité de commande de processus inclut un processeur (P) et une mémoire (M) contenant une séquence d'assemblage étalonnée et des coordonnées de bac prédéterminées pour chacun de la pluralité de bacs de composants , et est programmée pour :
    détecter, via le dispositif lumineux (30), une instance de rupture de faisceau dans laquelle le faisceau lumineux (32) est interrompu ou rompu ;
    caractérisé en ce que le plan fixe (32P) se situe entre un opérateur (40) et la pluralité de bacs de composants (22), dans lequel le plan fixe est divisé en un quadrillage virtuel (52) dans lequel chaque segment ou pixel possède une paire de coordonnées en deux dimensions, 2D, correspondants,
    et l'unité de commande de processus (12) est programmée pour :
    déterminer des coordonnées 2D de la rupture de faisceau comme l'une des paires de coordonnées 2D ;
    déterminer des coordonnées de bac 2D correspondantes d'un bac prévu via la séquence d'assemblage étalonnée ;
    comparer les coordonnées 2D déterminées de la rupture de faisceau aux coordonnées de bac 2D correspondantes du bac prévu ; et
    exécuter une action de commande par rapport au poste de travail à prélèvement manuel quand les coordonnées 2D déterminées de la rupture de faisceau ne correspondent pas aux coordonnées de bac 2D correspondantes du bac prévu.
  2. Système selon la revendication 1, dans lequel la source lumineuse (30) inclut un scanner laser qui oscille en continu le faisceau laser à l'intérieur du plan fixe (32P).
  3. Système selon la revendication 1, dans lequel la source lumineuse (30) inclut une pluralité de projecteurs laser stationnaires qui projettent le faisceau lumineux sous la forme d'une pluralité de faisceaux lumineux (32) le long du plan fixe (32P).
  4. Système selon l'une quelconque des revendications précédentes, comprenant en outre un dispositif indicateur (48) en communication avec l'unité de commande de processus (12), dans lequel l'unité de commande de processus est en outre programmée pour activer de manière sélective le dispositif indicateur en tant que l'action de commande.
  5. Système selon la revendication 4, dans lequel le dispositif indicateur (48) inclut une pluralité de lampes ayant chacune une couleur différente, et dans lequel l'action de commande est une illumination d'une de la pluralité de lampes.
  6. Système selon la revendication 4 ou 5, dans lequel le dispositif indicateur (48) inclut un haut-parleur (S), et dans lequel l'action de commande est une diffusion d'une tonalité audible via le haut-parleur.
  7. Système selon l'une quelconque des revendications 4 à 6, dans lequel le dispositif indicateur (48) inclut un dispositif tactile qui vibre en tant que l'action de commande supplémentaire.
  8. Système selon l'une quelconque des revendications précédentes, comprenant en outre un écran d'affichage (14), dans lequel l'action de commande inclut une présentation d'un message texte via l'écran d'affichage.
  9. Système selon l'une quelconque des revendications précédentes, dans lequel chacun des bacs de composants (22) inclut une lampe d'invite (25), et dans lequel l'unité de commande de processus (12) active sélectivement l'une des lampes d'invite en tant que l'action de commande.
  10. Procédé de commande d'un système de commande de position pour un poste de travail à prélèvement manuel (10) possédant une pluralité de bacs de composants (22), le procédé comprenant :
    la fourniture d'une séquence d'assemblage étalonnée et de coordonnées de bac prédéterminées pour chacun de la pluralité de bacs de composants ;
    la projection d'un faisceau lumineux (32) le long d'un axe fixe (32P) via un dispositif lumineux (30) ; et la détection, via une unité de commande de processus (12) et du dispositif lumineux (30), d'une instance de rupture de faisceau dans laquelle le faisceau lumineux (32) est interrompu ou rompu ;
    caractérisé par la localisation du plan fixe (32P) entre un opérateur (40) et la pluralité de bacs de composants (22), et la division du plan fixe en un quadrillage virtuel (52) dans lequel chaque segment ou pixel du quadrillage virtuel possède une paire de coordonnées en deux dimensions, 2D, correspondantes,
    la détection des coordonnées 2D de la rupture de faisceau comme l'une des paires de coordonnées 2D ; la détermination des coordonnées de bac 2D correspondantes d'un bac prévu via la séquence d'assemblage étalonnée ;
    la comparaison des coordonnées 2D déterminées de la rupture de faisceau aux coordonnées de bac 2D correspondantes du bac prévu via l'unité de commande de processus (12) ; et l'exécution d'une action de commande par rapport au poste de travail à prélèvement manuel via l'unité de commande de processus (12) quand les coordonnées 2D déterminées de la rupture de faisceau ne correspondent pas aux coordonnées de bac 2D correspondantes du bac prévu.
  11. Procédé selon la revendication 10, dans lequel la source lumineuse (30) inclut un scanner laser, et dans lequel la projection d'un faisceau lumineux (32) inclut l'oscillation en continu du faisceau laser à l'intérieur du plan fixe (32P).
  12. Procédé selon la revendication 10, dans lequel la source lumineuse (30) inclut une pluralité de projecteurs laser stationnaires, et dans lequel la projection du faisceau lumineux (32) inclut la projection d'une pluralité de faisceaux lumineux le long du plan (32P).
  13. Procédé selon l'une quelconque des revendications 10 à 12, dans lequel l'exécution de l'action de commande inclut l'activation sélective d'un dispositif indicateur (48) en tant que l'action de commande.
  14. Procédé selon l'une quelconque des revendications 10 à 13, dans lequel l'exécution de l'action de commande inclut au moins une action parmi l'activation d'une lampe d'invite (25) sur l'un des bacs de composants (22), la diffusion d'une tonalité audible via un haut-parleur (S) et l'activation d'un dispositif tactile (48) pour amener le dispositif tactile à vibrer.
  15. Procédé selon l'une quelconque des revendications 10 à 14, dans lequel l'exécution de l'action de commande inclut la présentation d'un message texte via un écran d'affichage (14).
EP14180487.2A 2014-05-30 2014-08-11 Surveillance de position à base de lumière d'une station de travail Not-in-force EP2957973B1 (fr)

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Application Number Priority Date Filing Date Title
US14/291,576 US9372278B2 (en) 2014-05-30 2014-05-30 Light-based position control of a manual picking process

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EP2957973A1 EP2957973A1 (fr) 2015-12-23
EP2957973B1 true EP2957973B1 (fr) 2017-09-27

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EP (1) EP2957973B1 (fr)
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JP6399437B2 (ja) 2014-06-04 2018-10-03 パナソニックIpマネジメント株式会社 制御装置及びそれを用いた作業管理システム
DE102017002962A1 (de) * 2016-04-22 2017-10-26 Sew-Eurodrive Gmbh & Co Kg Verfahren zum Herstellen in einer Fertigungszelle einer Fertigungsanlage und Fertigungsanlage zur Durchführung des Verfahrens
DE102016220352A1 (de) * 2016-10-18 2018-04-19 B. Braun Melsungen Ag Manuelles Kommissioniersystem
DE202017001497U1 (de) * 2017-03-21 2017-05-15 Rudolph Logistik Gruppe GmbH & Co. KG Vorrichtung zur fehlerfreien Anordnung eines Bestückungsbehälters
IT201700085336A1 (it) 2017-07-26 2019-01-26 Comau Spa "Dispositivo programmabile di assistenza ad un operatore in un ambiente di produzione"
EP3647890B1 (fr) 2018-10-29 2022-03-16 Omron Corporation Système d'assemblage et procédé pour faire fonctionner un système d'assemblage
CA3131217A1 (fr) * 2019-02-21 2020-08-27 Ops Solutions Llc Surveillance acoustique ou vibratoire dans un systeme d'assemblage guide

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US6753776B2 (en) 2000-08-25 2004-06-22 Scientific Technologies Incorporated Presence sensing system and method
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EP2686254B1 (fr) 2011-03-17 2018-08-15 SSI Schäfer Automation GmbH Commande et surveillance d'une installation de stockage et de préparation des commandes par le mouvement et la voix
FR2992875B1 (fr) 2012-07-05 2015-06-19 Schneider Electric Ind Sas Dispositif autonome employe dans un systeme d'aide a l'assemblage d'un produit

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US9372278B2 (en) 2016-06-21
EP2957973A1 (fr) 2015-12-23
MX348195B (es) 2017-05-29
MX2014010469A (es) 2015-11-30
CA2859116A1 (fr) 2015-11-30
CA2859116C (fr) 2016-11-01
US20150346383A1 (en) 2015-12-03

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